RCS-FT1 Control unit RCS-FC1. Cargo crane Radio control device (Specified low power radio type) Transmitter MODEL. Publication No.

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1 Publication No. W E 01 Cargo crane Radio control device (Specified low power radio type) Transmitter RCS-FT1 Control unit RCS-FC1 MODEL 2006 PRINTED IN JAPAN 0610 K

2 Foreword Foreword This service manual covers radio control device (specified low power radio type) provided to cargo cranes in the chart below. In undertaking repair, refer to the separate operation and maintenance manual and parts catalog for pertinent information. If the parts replacement is required, check the disassembly and order units from the applicable parts catalog. Cargo crane specification No. that this manual is applicable TM-30Z TM-36Z TM-36Z TM-36Z TM-36Z TM-50Z TM-50Z TM-50Z TM-56Z Please note that, for product improvement, some changes may have been incorporated in the machine that are not covered in this manual. 1 W E

3 Part no. of the main parts composing radio control device Part no. of the main parts composing radio control device August, 2006 Australian specification cargo crane specifications number Control valve (type) Part no. of the main parts composing radio control device Accelerator cylinder (type) Control unit Communication unit (type) Transmitter (type) TM-30Z TM-36Z TM-36Z TM-36Z NACHI (A-D2B-7193B) Control unit FUTABA (RCS-FC1) FUTABA (RCS-FT1) TM-36Z NACHI (HSP-D2B-7196A) NACHI (C-D2B-7255A) Communication unit TM-50Z TM-50Z TM-50Z FUTABA (RCS-FR1) TM-56Z SANWA SANWA (RMC-6T926-24) (AC ) 2 W E

4 Contents 1. Outline of radio control system Function of radio control system Hook-in function (Hook-in specification) Hook-out function (Hook-in specification) Speed change mode function Auto accelerator function (Resetting auto accelerator function) Emergency overwinding switch function Remote and radio control combination function Emergency stop switch function Alarm Function Structure of control valve ZR300ZR360ZR500ZR560 series structure of control valve(nachi) Hydraulic circuit General view RGB block Telescoping, Winch, Elevating, Swing Jack Wiring connection drawing ZR500ZR560 series structure of control valve(sanwa) Hydraulic circuit General view Front cover Solenoid valve Telescoping, Winch, Elevating, Swing Jack 2, Jack Wiring connection drawing Connector detail drawing Structure of accelerator cylinder ZR300ZR360ZR500ZR560 series structure of accelerator cylinder (NACHI) Hydraulic circuit General view ZR500ZR560 series structure of accelerator cylinder (SANWA) Hydraulic circuit General view Function of control valve and accelerator cylinder ZR300ZR360ZR500ZR560 series function of control valve and accelerator cylinder(nachi) RGB block RGB block Detail drawing of solenoid valve(sa/sb) Calculation of deviation and pulse width ZR500ZR560 series function of control valve and accelerator cylinder (SANWA) Front cover Front cover Solenoid valve Solenoid valve Detail drawing of solenoid valve(sa/sb) Functions of transmitter and control unit Name of each part Components Specific identification code (ID code) Self-diagnosis function Program number W E

5 Contents 7. Failure and remedy Failure remedy check flow chart Error No. list (Control unit) Transmitter (LCD) with a liquid crystal display error No. list F model radio control ID registration and adjustment procedures Components ID registration Adjustment mode function (Example) Idle UP adjustment function Other adjustment functions Engine revolution adjustment when mounting Adjustment mode operation procedures when mounting Error number display list Control unit error Transmitter (LCD) with a liquid crystal display error No. list ID registration and special specification setting procedures Special specifications setting list Setting pressure table of control valve ZR300ZR360ZR500ZR560 series (NACHI) ZR500ZR560 series (SANWA) W E

6 Outline of radio control system 1. Outline of radio control system Block diagram 1. For crane operation, boom telescoping, winch, boom elevation, boom swing and accelerator are controlled by determining positions of control valve spool and accelerator cylinder rod by feedback type digital proportional valve. 2. Command signal from transmitter and signal from differential transformer for feedback are respectively converted into analog and digital signals, and then inputted into the microcomputer in the control unit. 3. When an operation select switch and a speed control lever on the transmitter are operated, (1) A micro computer in the control unit transmits drive pulse to the solenoid valve corresponding to the command from the transmitter. (4) If it is deviated from the target position due to leakage from the valve after it is positioned, the differential transformer detects the deviation, and the position is corrected by drive pulse from the control unit. 4. The control cylinder is directly connected to the spool, and controls hydraulic pressure to the actuator. 5. In the case of manual operation mode (When power for the transmitter is OFF.) Even in manual operation mode, actuation of the control cylinder is detected by the differential transformer, and is fed back to the control unit. (2) As reduced hydraulic pressure is supplied to the driving solenoid valves (SA, SB), the control cylinder is actuated. (3) Actuation of the control cylinder is detected by the differential transformer, and is fed back to the control unit, and then the control cylinder moves to a target position equivalent to a pulling amount of the control lever, and is positioned. 3 W E

7 Function of radio control system 2. Function of radio control system 2.1 Hook-in function (Hook-in specification) 1. While the hook stowing switch on the transmitter is depressed, operation is in the following status. (1) The unload solenoid valve (SV1) is turned on, and is loaded. (2) The low pressure relief valve is actuated. [The low pressure relief solenoid valve (SV2) is turned on.] (3) The winch spool moves to the hoist-up side by 6mm. (4) When the speed control lever is pulled, the engine speed increases to medium speed. (The accelerator cylinder moves by 8mm at maximum.) (5) The automatic stop function for the overwinding prevention device is released. Additionally, the contact point in the overwinding detecting switch changes from ON Close to OFF Open, movement amount of the winch spool decreases from 6mm to 4mm. The engine speed drops to idling. 2. In the case of manual operation mode While the hook stowing switch on the panel (both sides) of the crane body is depressed, operation is in the same status as in the above to. However, the engine speed is kept in the idle-up status. 2.2 Hook-out function (Hook-in specification) 1. While the hook take-out switch on the transmitter is depressed, operation is in the following status. (1) The unload solenoid valve (SV1) is turned on, and is loaded. (2) The winch spool moves to hoist-down side by 3mm. (3) The boom elevation spool moves to the raising side by 6mm. (4) The idle-up function is actuated. (The accelerator cylinder moves by 4mm.) 2.3 Speed change mode function Engine speed is controlled by changing speed change mode, and the following two types of speeds other than high speed can be adjusted. (1) Fine speed mode Engine speed is not increased even by pulling the speed control lever more. Additionally, the control valve is not fully opened even if the speed control lever is pulled to its end. Therefore, the crane is operated at slow speed. (2) Medium speed mode The engine speed is not increased above medium speed even by pulling the speed control lever to the maximum. This function is effective only when radio-control operation is performed. The above function is not activated for manual operation. 1. Setting of fine speed mode When the mode is changed to the fine speed mode, operation is in the following status. (1) Maximum moving amounts of the boom telescoping spool, winch spool, boom elevation spool and boom swing spool decrease from 6mm to 4mm. The respective spools are actuated in a range of 0 to 4mm. (2) Even if the speed control lever is operated, the engine speed is kept in a constant status. (The accelerator cylinder moves by 4mm and holds the status.) 2. Setting of medium speed mode When the mode is changed to medium speed mode, operation is in the following status. (1) Maximum moving amounts of the boom telescoping spool, boom elevation spool and boom swing spool decrease from 6mm to 4mm. Maximum moving amount of the boom elevation spool is 6mm. (2) Even if the speed control lever is operated, the engine speed increases only to medium speed. (The accelerator cylinder moves by 8mm at maximum.) (5) When contact point in the overwinding detecting switch changes from OFF Open to ON Close with the speed control lever pulled, the engine speed increases. (The accelerator cylinder moves by 12mm at maximum.) 4 W E

8 Function of radio control system 2.4 Auto accelerator function (Resetting auto accelerator function) [NOTICE] The auto accelerator function is only for the manual operation mode. 1. When the auto accelerator switch on the panel (left) of the crane body is turned OFF, the engine speed is kept in a constant status even if any of the boom telescoping, winch, boom elevation and boom swing is operated. (The accelerator cylinder moves by 4mm and holds the status.) 2.6 Remote and radio control combination function 1. If radio-control operation cannot be performed due to radio interference, radio control operation can be changed to remote control operation. 2. Connect the remote control transmitter to the control unit and turn ON the power for the remote control transmitter, then a mode indicator on the control unit indicates L3 for remote control operation mode, and remote control operation can be performed. 2.5 Emergency overwinding switch function [NOTICE] The emergency overwinding switch function is for taking emergency action when operations of hook hoist-up, boom extension or boom raising cannot be performed due to failure of the overwinding prevention device. (Cause of failure of the overwinding prevention device is wire breakage of the overwinding detecting circuit or earth defect in the boom part etc.) The Emergency overwinding switch function is effective only for manual operation mode. 2.7 Emergency stop switch function 1. Press the emergency stop switch when control cannot be made by the operation switch or lever, or a dangerous state occurs depending on surrounding conditions. If the emergency stop switch is depressed, the crane does not operate. For position of the emergency stop switch and how to operated it, contact our sales representative or agent. 1. The automatic stop is reset and the engine speed is kept in a constant status when the boom telescoping, winch, boom elevation or boom swing operation lever is operated with the emergency overwinding switch on the panel of the crane body being depressed. (The accelerator cylinder moves by 4mm and holds the status.) 5 W E

9 Function of radio control system 2.8 Alarm Function 1. When any abnormality occurs in the system, improper operation is performed, or attention to operation is drawn, voice alarms such as the following are issued. Cause 1Automatic stop due to failure of radio control system Computer diagnoses that a serious error has occurred in the system. 2Stop due to overwinding 1. Hook block is overwound. 2. Boom extension, boom raising or hoist-up operation is attempted while the hook block is overwound. 3Control lever out of neutral position Immediately after the PTO is connected A control lever is out of the neutral position. Alarm Beep.3 times repeated Beep.1 time Beep.3 times repeated During radio-control or remote-control operation after the PTO is connected A control lever does not return to the neutral position even though the corresponding control switch on the transmitter is returned to the neutral position. 4Weak batteries (radio control) A control switch on the transmitter is operated while the battery voltage for the transmitter is low. 5Hook block stowing operation Hook-in switch on the transmitter or control panel is pressed. 6Hook block take-out operation Hook-out switch on the transmitter or control panel is pressed. 7Unsetting of outriggers Before setting the outriggers Any operation other than jacking is attempted while the outriggers are unset. After setting the outriggers Any jack is off the ground during crane operation. 8Boom angle restricted area Boom extension, boom lowering, hoist-up or swing operation is attempted while the boom is at the fully raised or lowered position. 9Overload limit alarm The crane is in an overloaded condition. Ding-dong.1 time Ding-dong.1 time Ding-dong.1 time Beep.1 time Beep.1 time Beeprepeated Beep.1 time Beep.1 time Beeprepeated 6 W E

10 Function of radio control system Cause Alarm 10Upon setting of a working height limit A working height limit is set. 11Upon cancellation of the working height limit The working height limit is canceled. 12Stop at the working height limit 1. The boom height reaches the limit value. 2. Boom extension or boom raising operation is attempted while the boom height is at the limit. 13Error in the AML-related system An error exists in the AML-related system. Ding-dong.1 time Ding-dong.1 time Beep.1 time Beep.3 times repeated 7 W E

11 Structure of control valve (NACHI) 3. Structure of control valve 3.1 ZR300ZR360ZR500ZR560 series structure of control valve(nachi) Hydraulic circuit 8 W E

12 Structure of control valve (NACHI) General view 9 W E

13 Structure of control valve (NACHI) RGB block 10 W E

14 Structure of control valve (NACHI) Telescoping, Winch, Elevating, Swing Jack 11 W E

15 Structure of control valve (NACHI) Wiring connection drawing 12 W E

16 Structure of control valve (NACHI) Connector detail drawing Terminal Signal Signal Name Destination Terminal Signal Metal connector pin array Signal Name Destination Terminal Signal Signal Name Destination A SW7 O/R left extension a SW10 Emergency overwind z FB1-1 Telescoping B SW6 O/R right extension b SW9 Accelerator release AA FB2-2 Winch C SW5 Tipping alarm left c SW8 BB FB2-1 Winch D SW4 Tipping alarm right d OUT4 SL indicator lamp CC FB3-2 Elevating E EX-TXD O/R serial output e OUT3 Spare DD FB3-1 Elevating F EX-RXD O/R serial input f HORN Horn output EE FB4-2 Swing G OUT7 Jack operation g OUT2 SL jack extension FF FB4-1 Swing H OUT8 SL unload output h OUT1 SL jack retraction GG FB5-2 Accelerator J OUT5 SL hoisting up i UNLOAD Unload relief power supply output HH FB5-1 Accelerator K OUT6 SL hoisting down j LOW Low pressure relief power supply output L SA1 Telescoping extension k MBSRC Battery power supply input M SB1 Telescoping retraction m MBGND Battery power supply input N SA2 Hoisting up n BOOT Maintenance terminal P SB2 Hoisting down p GND Jack neutral position earth input R SA3 Boom lowering q OSC1 S SB3 Boom raising r OSC2 T SA4 Left swing s FB-GND U SB4 Right swing t AUDI01 Speaker V SA5 Accelerator up u AUDI02 Speaker W SB5 Accelerator down v SW3 Overwind detector X SW13 Jack neutral position w SW2 Maintenance terminal Y SW12 Hook-in x SW1 Maintenance terminal Z SW11 Distinguisher for hook-in specification y FB1-2 Telescoping (NOTE) Terminal marked with is plugged depending on the specification. 13 W E

17 Structure of control valve (SANWA) 3.2 ZR500ZR560 series structure of control valve(sanwa) Hydraulic circuit 14 W E

18 Structure of control valve (SANWA) General view 15 W E

19 Structure of control valve (SANWA) Front cover 16 W E

20 Structure of control valve (SANWA) Solenoid valve 17 W E

21 Structure of control valve (SANWA) Telescoping, Winch, Elevating, Swing Jack 2, Jack 1 18 W E

22 Structure of control valve (SANWA) Wiring connection drawing 19 W E

23 Structure of control valve (SANWA) Connector detail drawing Terminal Signal Signal Name Destination Terminal Signal Metal connector pin array Signal Name Destination Terminal Signal Signal Name Destination A SW7 O/R left extension a SW10 Emergency overwind z FB1-1 Telescoping B SW6 O/R right extension b SW9 Accelerator release AA FB2-2 Winch C SW5 Tipping alarm left c SW8 BB FB2-1 Winch D SW4 Tipping alarm right d OUT4 SL indicator lamp CC FB3-2 Elevating E EX-TXD O/R serial output e OUT3 Spare DD FB3-1 Elevating F EX-RXD O/R serial input f HORN Horn output EE FB4-2 Swing G OUT7 Jack operation g OUT2 SL jack extension FF FB4-1 Swing H OUT8 SL unload output h OUT1 SL jack retraction GG FB5-2 Accelerator J OUT5 SL hoisting up i UNLOAD Unload relief power supply output HH FB5-1 Accelerator K OUT6 SL hoisting down j LOW Low pressure relief power supply output L SA1 Telescoping extension k MBSRC Battery power supply input M SB1 Telescoping retraction m MBGND Battery power supply input N SA2 Hoisting up n BOOT Maintenance terminal P SB2 Hoisting down p GND Jack neutral position earth input R SA3 Boom lowering q OSC1 S SB3 Boom raising r OSC2 T SA4 Left swing s FB-GND U SB4 Right swing t AUDI01 Speaker V SA5 Accelerator up u AUDI02 Speaker W SB5 Accelerator down v SW3 Overwind detector X SW13 Jack neutral position w SW2 Maintenance terminal Y SW12 Hook-in x SW1 Maintenance terminal Z SW11 Distinguisher for hook-in specification y FB1-2 Telescoping (NOTE) Terminal marked with is plugged depending on the specification. 20 W E

24 Structure of accelerator cylinder (NACHI) 4. Structure of accelerator cylinder 4.1 ZR300ZR360ZR500ZR560 series structure of accelerator cylinder (NACHI) Hydraulic circuit General view 21 W E

25 Structure of accelerator cylinder (SANWA) 4.2 ZR500ZR560 series structure of accelerator cylinder (SANWA) Hydraulic circuit General view 22 W E

26 Function of control valve (NACHI) 5. Function of control valve and accelerator cylinder 5.1 ZR300ZR360ZR500ZR560 series function of control valve and accelerator cylinder(nachi) RGB block 1. Back pressure regulating valve C It ensures the minimum hydraulic pressure required to actuate control cylinders. 2. Reducing valve D It reduces hydraulic pressure applied to control cylinders to the constant pressure. 3. Main relief valve E It limits the maximum pressure of the hydraulic system. 4. Low pressure relief valve HHook-in specification It limits the maximum hydraulic pressure during hook block stowing. 5. Unload solenoid valvesv1 It becomes energized and loads the circuit in either condition of 1 or 2 below: 1 control switch of the transmitter is operated at the radio control mode. 2 control lever on the crane main body comes out of neutral at the manual control mode. 6. Solenoid valve (for low pressure relief)sv2 Hook-in specification It is energized during hook block stowing, making the low pressure relief valve effective. 6. Provisional treatment in emergency Emergency loading adjusting screw If the circuit cannot be loaded due to electrical failure, it can be loaded by mechanical means. When the adjusting screw on unload solenoid valve (SV1) is tightened, the circuit will be loaded, enabling manual operation of the crane. WARNING The procedure described in this section is used to stow the crane in an emergency. Do not perform this procedure during normal crane operation. 23 W E

27 Function of control valve (NACHI) RGB block 24 W E

28 Function of control valve (NACHI) Detail drawing of solenoid valve(sa/sb) NOTE This figure is for the illustration of the operational principle. The solenoid valve (SA/SB) of the control valve and the solenoid valve (SA/SB) of the accelerator cylinder work on the same operational principle. 1. Deenergized state 2. Energized state 25 W E

29 Function of control valve (NACHI) 3. Operation of fast-response solenoid valve (1) (SOLA OFFSOLB OFF) SOL A OFF SOL B OFF Q Q IW Operation of fast-response solenoid valve (2) (SOLA OFFSOLB ON) SOL A OFF SOL B ON Q R IW Operation of fast-response solenoid valve (3) (SOLA ONSOLB OFF) 26 W E

30 Function of control valve (NACHI) Calculation of deviation and pulse width The hydraulic power unit is controlled by the control part as follows: 1. While the control unit does not work, the transistor of the receiver is OFF and the solenoid valves are connected to the tank. In this condition, the control cylinder is kept to the neutral position by the spring force. 4. The deviation will be calculated after 40 ms of a pulse output cycle. If the deviation is within the allowance, the deenergized solenoid valve will become energized. If the deviation is out of the allowance, the solenoid valve will remain deenergized for a time according to the deviation. 2. When the control unit comes into operation, the transistors for SA and SB are turned ON and energize the solenoid valves, making both solenoid valves connected to the pump. In this condition, the control cylinder will be kept to the neutral position by pressure from the pump. 5. When the deviation is reduced within the allowance and the control cylinder reaches desired position, both solenoid valves will be energized and keep the control cylinder at the position. 3. Then the solenoid valve in the direction that is needed to actuate will be deenergized and connect to the tank. The other valve will remain energized and will be connected to the pump. Thus the oil from the pump will flow into the control cylinder and move its piston. Time to deenergize the solenoid valve mainly depends on deviation. 27 W E

31 Function of control valve (SANWA) 5.2 ZR500ZR560 series function of control valve and accelerator cylinder (SANWA) Front cover 1. Back pressure regulating valve C It ensures the minimum hydraulic pressure required to actuate control cylinders. 2. Reducing valve D It reduces hydraulic pressure applied to control cylinders to the constant pressure. 3. Relief valve F (for overload) It releases the high pressure developed in the circuit to the control cylinder. 4. Relief valve (works when filter is clogged) When the filter is clogged, this relief valve leads the hydraulic pressure to reducing valve. 5. Unload relief valve When it works in combination with the low pressure relief valve, the hydraulic pressure is low during hook block stowing. When it works in combination with the unload solenoid valve, the pressurized oil returns to the tank short of the back pressure regulating valve. It helps to make the crane inactive in case of overwinding and electrical failure by reducing the hydraulic pressure to zero. 28 W E

32 Function of control valve (SANWA) Front cover 29 W E

33 Function of control valve (SANWA) Solenoid valve 1. Main relief valve E It limits the maximum pressure of the hydraulic system. 2. Low pressure relief valve HHook-in specification It limits the maximum hydraulic pressure during hook block stowing Unload solenoid valvesv1 It becomes energized and loads the circuit in either condition of 1 or 2 below: 1 control switch of the transmitter is operated at the radio control mode. 2 control lever on the crane main body comes out of neutral at the manual control mode. 4. Solenoid valve (for low pressure relief)sv2 Hook-in specification It is energized during hook block stowing, making the low pressure relief valve effective. 5. Provisional treatment in emergency Stop valve If the circuit cannot be loaded due to electrical failure, it can be loaded by mechanical means. When the stop valve is screwed in, the circuit will be loaded. WARNING The procedure described in this section is used to stow the crane in an emergency. Do not perform this procedure during normal crane operation. 30 W E

34 Function of control valve (SANWA) Solenoid valve 31 W E

35 Function of control valve (SANWA) Detail drawing of solenoid valve(sa/sb) NOTE This figure is for the illustration of the operational principle. The solenoid valve (SA/SB) of the control valve and the solenoid valve (SA/SB) of the accelerator cylinder work on the same operational principle. 1. Deenergized state 2. Energized state 32 W E

36 Functions of transmitter and receiver (manufactured by FUTABA) 6. Functions of transmitter and control unit Name of each part 6.1 Components 6.2 Specific identification code (ID code) Specific identification code (ID code) is set to combination of transmitter and control unit. When replacing either one of the transmitter or control unit, register its identification code for the transmitter, and set its specification for the control unit. Unless registration or setting is carried out, radio-control operation is not normally performed. [NOTICE] For how to register the identification code, refer to the Failure and remedy in Table Self-diagnosis function The control unit has a self-diagnosis function. The mode indicator indicates L0, L1, 0 or L3 if there is no abnormality, and indicates error numbers of 11 to 89 if there is any error. [NOTICE] If there are two or more abnormalities, error numbers are sequentially indicated by flashing. For contents of error numbers, refer to the chapter of Failure and remedy. 6.4 Program number The control unit has a function to indicate program number. If the maintenance mode switch on the control unit is depressed for two seconds or longer when the PTO is connected, 01 for program number and ** for change history are indicated, and then the LL flashes. When the PTO is disconnected, the ID registration mode is reset. (Only ID registration mode is displayed.) 33 W E

37 Failure and remedy 7. Failure and remedy 7.1 Failure remedy check flow chart 34 W E 34

38 Failure and remedy 35 W E

39 Failure and remedy 36 W E

40 Failure and remedy 37 W E

41 Failure and remedy 38 W E

42 Failure and remedy 39 W E

43 Failure and remedy 40 W E

44 Failure and remedy 41 W E

45 Failure and remedy 42 W E

46 Failure and remedy 7.2 Error No. list (Control unit) [NOTICE] For abnormalities whose symbols below the box of unload solenoid valve (SV1) are marked with, the unload solenoid valve (SV1) is turned on when radio-control operation or manual operation is performed, and then the valve is loaded. As the valve is loaded, a part of radio-control operation corresponding to the error No. cannot be performed. For abnormalities whose symbols below the box of unload solenoid valve (SV1) are marked with, the unload solenoid valve (SV1) is kept turned off even if radio-control operation or manual operation is performed, and then the valve is not loaded. Both of radio-control operation and manual operation cannot be performed. Additionally, there is a temporary remedial method to operate the crane by mechanically causing loading of the valve. Refer to the item of the stop valve in the Function of control valve. For valve manufactured by NACHI: 10P For valve manufactured by SANWA: 15P Unload solenoid Error No. valve (SV1) 11 Location of failure estimated Remedy Low pressure relief solenoid wire breakage error (1) Wire breakage of low pressure relief solenoid (2) Wire breakage of wiring and connectors, etc., for the above (1), contact failure, wrong wiring, etc. (3) Failure of driving transistor (IC) for the above Replace the control unit. (1) (control unit side) Check wire breakage with tester, etc., to repair or replace. 12 Transmitter CPU error Replace the transmitter. (1) Operation select switch short-circuit, or abnormality of WDT, A/D converter and ID circuit 13 Transmitter operation select switch error 30 (Boom telescoping) 31 (Winch) 32 (Boom elevation) 33 (Boom swing) 34 (Accelerator) (1) When power for the transmitter is turned ON in the case that the operation select switch is not on the neutral position. Differential transformer neutral error (1) Corresponding control cylinder is not at the neutral position. (2) Failure of corresponding differential transformer control unit 35 Jack neutral error (1) The jack spool is not at neutral. Return the operation select switch to the neutral position and turn ON the power. Replace the transmitter if the error is not recovered to normal. Move the control cylinder by manual operation, and check if the corresponding error No. is turned off. Adjust shims for the transformer mounting seat if it is turned off. Replace the differential transformer unless it is turned off. Replace the control unit when the error is not recovered to normal even if the above remedy is taken. Move the jack spool by manual operation, and check if the error No. is turned off. Replace the neutral detecting switch unless it is turned off. 43 W E

47 Failure and remedy Error No. 40 (Boom telescoping) 41 (Winch) 42 (Boom elevation) 43 (Boom swing) 44 (Accelerator) 45 (Boom telescoping) 46 (Winch) 47 (Boom elevation) 48 (Boom swing) 49 (Accelerator) 50 (Boom telescoping) 51 (Winch) 52 (Boom elevation) 53 (Boom swing) 54 (Accelerator) 36 (Jack) 55 (Boom telescoping) 56 (Winch) 57 (Boom elevation) 58 (Boom swing) 59 (Accelerator) 37 (Jack) 60 (Boom telescoping) 61 (Winch) 62 (Boom elevation) 63 (Boom swing) Unload solenoid valve (SV1) Location of failure estimated Differential tran Replace the control unit. Replace the control unit.sformer output error (1) Failure of corresponding differential transformer control unit circuit Remedy Replace the control unit if the error is recovered by replacing it. Differential transformer wire breakage error (1) Coil on the primary side or secondary side of the corresponding differential transformer is broken. (2) Wire breakage of wiring and connectors, etc., for the above (1), contact failure, wrong wiring, etc. (3) Failure of corresponding differential Replace the control unit. transformer control unit circuit for the above (1) Solenoid SA side wire breakage error (1) Wiring from the corresponding solenoid SA to the control unit is broken (2) Wire breakage of wiring and connectors, etc., for the above (1), contact failure, wrong wiring, etc. (3) Failure of driving transistor (IC) for the above Replace the control unit. (1) (control unit side) Check wire breakage with tester, etc., to repair or replace. Check wire breakage with tester, etc., to repair or replace. Solenoid SB side wire breakage error Check wire breakage with tester (1) Wiring from the corresponding solenoid SB to etc to repair or replace. the control unit is broken (2) Wire breakage of wiring and connectors for the above (1), contact failure, wrong wiring etc. (3) Failure of driving transistor (IC) for the above Replace the control unit. (1) (control unit side) Control cylinder neutral return error (1) Corresponding control cylinder does not smoothly operate due to inclusion of contaminants, etc. Or the control cylinder is locked on a position other than the neutral. Check operating status of the control cylinder by manual operation. Replace or repair the corresponding valve when it does not smoothly operate due to inclusion of contaminants, etc., and when it is locked. After turning OFF power for the transmitter, move the control cylinder by manual operation. In this case, if the error No. is turned off, it can be subsequently used, however, it is recommended to repair it at earlier time. 44 W E

48 Failure and remedy Unload solenoid Error No. valve (SV1) 70 Location of failure estimated Unload solenoid error (1) Wire breakage of unload solenoid (2) Breakage of unload solenoid wiring, contact failure of connector (3) Failure of unload solenoid driving transistor (IC) (control unit side) Remedy Check wire breakage with tester, etc., to repair or replace. Replace the control unit. 71 Solenoid coil short-circuit error (1) Some of the wirings from the unload solenoid, low pressure relief solenoid and driving solenoid (SA/SB) to the control unit are short-circuited with GND. (2) Short-circuit at wiring for the above (1), and at connector part, etc. (3) Short-circuit of solenoid common line (+24V) (4) Failure of each solenoid driving transistor (IC) (Control unit side) 72 Solenoid common line (+24V) wire breakage error (1) Wire breakage of solenoid common line (+24V), contact failure of connector part, wrong wiring, etc. 73 Differential transformer primary and secondary sides common line wire breakage error (1) Wire breakage of primary side common line or at connector parts, contact failure, wrong wiring, etc. (2) Wire breakage of secondary side GND common line or at connector parts, contact failure, wrong wiring, etc. (3) Failure of control unit excitation (oscillation) circuit (Control unit side) 80 Sum check error (1) CPU, memory, its peripheral circuit 81 A/D converter (1) A/D converter, multiplexer, etc V error (1) Abnormal drop or abnormal rise of battery voltage (2) Short-circuit, contact failure due to wrong wiring of battery wires 83 All differential transformer output error (1) Failure of all differential transformer control unit circuit, or failure of control unit 84 All transformer neutral error (1) Failure of all differential transformer control unit circuit, or failure of control unit Check short-circuit with tester, etc., to repair or replace. (Short-circuit is measured as if entire wiring is short-circuited. Therefore, separate wiring into some small divisions at connector parts for measurement.) Replace the control unit. Check wire breakage with tester, etc., to repair or replace. Check wire breakage with tester, etc., to repair or replace. Replace the control unit. Replace the control unit. Replace the control unit. Set the battery voltage inputted into the control unit within a range from 18 to 32V. Replace the control unit. Replace the control unit. 45 W E

49 Failure and remedy Error No. Unload solenoid valve (SV1) Location of failure estimated 85 Other errors in control unit (1) CPU, memory, its peripheral circuit Remedy Replace the control unit. 86 Control unit ID circuit error (1) ID circuit abnormality Replace the control unit. 87 Control unit communication microcomputer CPU Replace the control unit. error (1) WDT abnormality 88 WDT error Replace the control unit. (1) CPU, memory, its peripheral circuit (2) Program processing abnormality due to noise 89 Over-current Replace the control unit. 7.3 Transmitter (LCD) with a liquid crystal display error No. list Liquid crystal No. Name LED No, Remedy E98 Switch failure Replace the switch. E93 Speed lever failure Replace the speed lever. E94 Continuous operation limit error 13 Replace the switch. E91 Serial communications failure E92 Transmitter matching error Replace the transmitter or the E95 System failure communication unit. E96 Radio module failure E97 Memory failure 46 W E

50 F model radio control ID registration and adjustment procedures 8. F model radio control ID registration and adjustment procedures 8.1 Components LCD specifications radio control with liquid crystal display (Australia specifications) 47 W E

51 F model radio control ID registration and adjustment procedures 8.2 ID registration LCD specifications (with liquid crystal display) are LCD specifications (liquid crystal display) Controller (common) Maintenance mode switch (1) Turn ON the starter key of the vehicle side. The engine does not start. (2) Operate the PTO to connect and supply the power to the controller. (3) Keep pressing the maintenance mode switch of the controller for 2 seconds or more. (A soft position exists.) (4) After displaying the program number 01 (upper 2 digits) ** (change history), LL flashes. [NOTICE] The mode display lamp of the control unit changes from the manual mode L0 to the flashing display of the ID registration mode LL. (5) When the power switch is pressed while the horn switch of the radio control transmitter is pressed and held, it becomes the following display state. *LCD specifications: ID registration screen is displayed. Display of ID registration [NOTICE] The mode display lamp of the controller keeps flashing display of LL of ID registration mode. 48 W E

52 F model radio control ID registration and adjustment procedures (6) When communications are established, it becomes the following display state. *LCD specifications: ID registration completion screen is displayed. ID registration completion is displayed. The number on the bottom line individually differs. [NOTICE] The mode display lamp of the controller changes to the ID registration mode LL flashing. (7) When the swing select switch of the radio control transmitter is operated left, it moves to the special specification setting state, and the mode display lamp of the controller displays from the ID registration mode LL to flashing (or lighting) display of the special specification number 01. (when set: lighting, when not set: flashing) When the swing select switch of the radio control transmitter is operated right, it moves to the special specification setting state, and the mode display lamp of the controller displays from the ID registration mode LL to flashing (or lighting) display of the special specification number (final number.) (8) Every time the swing select switch of the radio control transmitter is operated left and right (up/down), the special specification number is displayed on the mode display lamp of the controller. Swing select switch (9) It is set by pressing the horn switch to the number to be set. (The special specification number lights.) When the horn switch is pressed again, it is released. (The special specification number flashes.) Press the horn switch [NOTICE] Make sure to check the valve manufacturer for the special specification number 19 and set. [Lighting = made by Sanwa, Flashing = made by Fujikoshi] [NOTICE] See the list at the end of this manual for the special specification number. 49 W E

53 F model radio control ID registration and adjustment procedures Display of special specification number Provisional special specification number [NOTICE] Operate the swing select switch and display the special specification number to set on the 7th segment of the LED of the controller, and press the horn switch once, and it changes from flashing to lighting. It is set when it becomes lighting. (10) Valve by Miwa [Special specification number 19 lighting setting] The solenoid valve is vertically attached. (11) Valve by Fujikoshi [Special specification number 19 flashing setting] The solenoid valve is horizontally attached. 50 W E

54 F model radio control ID registration and adjustment procedures (12) When the hook take-out switch is pressed once after setting, the serial number display of the already set special specification number is displayed on the 7th segment of the LED of the controller (when checking). When the hook take-out switch is pressed again, it returns to the state of (6). When pressed, the set number is sequentially displayed. (13) When the power of the radio control transmitter is cut, the ID registration mode is released. *LCD specifications: the ID registration completion of the liquid crystal display goes off. [NOTICE] After ID registration and special specification setting, make sure to turn off the power (main switch). Make sure to cut off the power to the controller. [NOTICE] (Turn off the power to Delete the past log and check the 0 point.) If it is operated as it is after setting, it does not normally act. Reference: 7th segment of the LED display LL = registration completion L0 = manual mode (when power on) L1 = radio control mode (when power of the transmitter is on) L2 = no setting L3 = remote control mode (when remote control unit is connected) L4 = no setting L5 = no setting L6 = no setting L7 = no setting L8 = no setting L9 = in re-connecting 51 W E

55 F model radio control ID registration and adjustment procedures 8.3 Adjustment mode function (Example) Idle UP adjustment function [NOTICE] According to the mounting procedures, the idle UP revolution must be adjusted. (Initial value: 4.0 mm) [NOTICE] The starter key of the vehicle side is kept on, the PTO is kept connected, the controller is kept energized. (1) While the User mode switch (LCD specifications) of the radio control transmitter is pressed and held, press the power switch, and it becomes the following display state. *LCD specification (with liquid crystal display): the adjustment mode screen is displayed. cc is displayed. [NOTICE] When changed over to the adjustment mode, the mode display lamp of the controller displays cc. c1 c2 c3 Up to c9 Elevation upside control Ascending order display Ascending order (2) Every time the elevation select switch of the radio control transmitter is operated upside or downside, the mode display lamp of the controller displays from c1 to c* (final number). c4 is displayed for idle up adjustment. Upside or downside of elevation operation 52 W E

56 F model radio control ID registration and adjustment procedures (3) In the state that the mode display lamp of the controller displays c4, press the horn switch. The mode display lamp of the controller displays the initial value or memorized value. Press the horn switch. [NOTICE] The mode display lamp of the controller displays the initial value 40 of the idle UP adjustment function. However, once it is adjusted, the value after the adjustment is memorized and the value (memorized value) is displayed when adjusting next time. At this time, the accelerator cylinder extends for 4.0 mm. [NOTICE] When the mode display lamp of the controller displays 40, it means that the accelerator cylinder acts for 4.0 mm when idle UP. (4) Operate the elevation select switch upside or downside again, and increase or decrease the number on the mode display lamp of the controller. For example, display 45 to actuate the accelerator cylinder for 4.5 mm when idle up. At this time, the accelerator cylinder extends for 4.5 mm. When the elevation select switch is operated upside, the numeric value increases. (5) Press the horn switch again in the state that the mode display lamp of the controller displays 45. The mode display lamp of the controller displays c4, and the memorized value is changed. At this time, the accelerator cylinder extends for 4.5 mm. Press the horn switch. (6) When the power of the radio control transmitter is turned off, the adjustment mode is released. 53 W E

57 F model radio control ID registration and adjustment procedures Other adjustment functions [NOTICE] 8.3.1(Example) the following adjustment is possible in the same manner as the idle UP adjustment function. Adjust them when necessary. c1 Hook out (elevation: elevating + winch: down) winch spool adjustment function The boom weight differs depending on the boom stage number or model, so in this system the winch spool stroke can be adjusted in a case of an inconvenience occurring in continuous operation. (Initial value 3.0 mm) c2 Hook out (telescoping: extension + winch: down) winch spool adjustment function The telescoping speed differs depending on the cylinder size or telescoping method, so in this system the winch spool stroke can be adjusted in a case of an inconvenience occurring in continuous operation. (Initial value 3.0 mm) c4 Idle UP adjustment function According to the mounting procedures, the idle up revolution must be adjusted. (Initial value 4.0 mm) Value after adjustment c5 Medium speed adjustment function According to the mounting procedures, the medium revolution must be adjusted. (RAC specification initial value 8.3 mm) Value after adjustment c8 Swing soft stop time (when high speed) adjustment function Only for the case of soft stop of swing, the stop time can be adjusted in this system for a request from a user. (Standard 1.0s) 54 W E

58 F model radio control ID registration and adjustment procedures 8.4 Engine revolution adjustment when mounting (1) Check the maximum engine revolution adjustment value in the mounting part selection chart. Always adjust in the order of (1) (7). Maximum engine revolution adjustment value A : mounting part selection chart min -1 (PTO of Tadano) (2) Set to the state that the bolt for a maximum revolution adjustment stopper of the crane is tightened. [NOTICE] Basically, the maximum engine revolution adjustment value is set with a link hole, so use the bolt for a stopper only for fine adjustment. Or use only when it exceeds the adjustment value with connecting to the link hole 9. Frame right side, from overhead (3) Start the engine and set to PTO ON. The engine revolution at this point is used as initial value and adjustment starts. Pull the cable from the governor link of the vehicle side (link of electric governor accelerator sensor, etc.), and measure the cable stroke or the governor stroke until it reaches the engine revolution adjustment value A from the initial value (idling). Select a link hole that is larger than the measured cable stroke and also the closest from the cable strokes of respective link holes in the table below, and attach an accelerator cable. At this time, secure looseness of the cable of the vehicle side for about 2 mm. And pay attention that the wiring resistance of the accelerator cable or the governor link application force does not get too large or exceed the value of the cable pulling force of the accelerator cylinder in the table below. If it exceeds the value, check that the cable is not bent like a dogleg again. Link hole Cable stroke Cable fixed position Cable pulling force 1 51mm A 10kg 2 47mm A 11kg 3 44mm A 12kg 4 41mm A 13kg 5 38mm B 14kg 6 35mm B 15kg 7 32mm B 16kg 8 29mm B 17kg 9 25mm B 18kg * Some vehicles of special specification that are already delivered may have only 5 link holes. Use the link if there is no problem with accelerator adjustment. [NOTICE] Check that the action amount of the accelerator sensor lever of the vehicle side is not exceeded when the cable is pulled at maximum by radio control operation shown in below. If exceeded, the accelerator sensor lever of the vehicle side or the relative parts may be damaged, so work with care. 55 W E

59 F model radio control ID registration and adjustment procedures (4)-1 Compare the engine revolution and the maximum engine revolution adjustment value A when the speed control lever is in full stroke by the winch up operation or down operation at the high speed mode of radio control operation. [NOTICE] The maximum revolution cannot be measured by manual operation and other operation of radio control. Always check it by the winch up operation or down operation with the radio control operation. To the maximum engine revolution adjustment value A the engine revolution in the above-described operation is, a: 10% (about 200 min -1 ) or higher --- return to (3) and select a link hole again. (Move to a link hole of downside.) b: High within the range of 0 to 10% (about 200 min -1 ) --- go to (4)-2 c: Low within the range of 5 to 0% (-100 min -1 )--- Selection of the link hole is OK, go to (5). d: -5% (about 100 min -1 ) or lower --- return to (3) and select a link hole again. (Move to a link hole of upside.) (4)-2 Extend the bolt for the maximum revolution adjustment stopper so that the link stops in the middle of the stroke, and lower the maximum engine revolution. Fix the bolt for a stopper with a locknut when it becomes the adjustment value A to A -100 min -1. (5) Adjustment of idle up revolution C When c4 is selected in the adjustment mode, the accelerator cylinder extends for 4.0 mm. At this time, check that the engine revolution is higher than the initial value of (3) and also about 700 min -1. If it is not approximately 700 min -1, adjust the accelerator cylinder stroke by the adjustment mode operation, and adjust the engine revolution to be within the range. If the initial value in (3) exceeds 700 min -1, adjust to approximately 50 min -1 higher than the initial value when the accelerator cylinder becomes the idle UP state. (6) Adjustment of medium engine revolution D When c5 is selected in the adjustment mode, the accelerator cylinder extends for 8.3 mm. At this time, check that the revolution becomes the intermediate value to intermediate value min -1 of the idle UP revolution C and the maximum engine revolution adjustment value A. If it is not the numeric value specified above, adjust the accelerator cylinder stroke by adjustment mode operation, and adjust the engine revolution to be within the range. (Example) When the maximum engine revolution adjustment value A is 2000 min -1 and the idle UP revolution C is 700 min -1, D is ( ) /2 = 1350 min -1 so adjust it to be within the range of 1350 to 1450 min -1. (7) Adjustment of manual jack revolution E Operate the jack with the manual lever, and check that the revolution E at that time is equivalent to the medium speed engine revolution D. When the revolution is high: adjust the rod length in the gap between the cam and the roller and make the gap larger to lower the revolution. When the revolution is low: adjust the rod length in the gap between the cam and the roller and make the gap smaller to raise the revolution. 56 W E